Introduction to the Electroforming Process.

Technically, it is a process of synthesizing a metal object by controlling the electrode position of metal passing through an electrolytic solution onto a metal or metalized form. More simply, a metal skin is built up on a surface that has been rendered electro conductive through the application of a conductive paint. Essentially, a metal part is fabricated from the plating itself. This differs from electroplating because the skin is much thicker and can exists as a self-supporting structure if the original matrix is removed. The object which is being electroformed can be a permanent part of the end of the product or it can be temporary (as in the case of wax), and can be removed later, leaving only the metal form the ‘electroform’. The advantage of the electroforming process is that it reproduces the form or mandrel to within 1-1000 microns without the shrinkage and distortion associated with other metal forming techniques such as casting, stamping or drawing. And, since the mandrel is machined as an outside surface, close dimensional tolerances and high surface finishes can be held and maintained on complex interior configurations.

This process is widely used in the engineering and jewellery industry, by craft workers and model makers. It is not very difficult and it allows you to obtain a high quality products but it takes much more time than an electroplating process. Electroforming is carried out using an electrolytic bath deposit the metal onto a conductive surface. Once the plated material has been built up to the desired thickness, the electroformed part is removed from the mandrel substrate. This process allows a high quality duplication of the mandrel and therefore helps to get a good quality of production. If we compare this process to other basic metal forming processes (casting, stamping, deep drawing, machining etc) electroforming is a very effective when requirements call for extreme tolerances, complexity or lightweight. The precision and resolution inherent in the photographically produced conductive patterned substrate, allows finer geometries to be produced to tighter tolerances while maintaining superior edge definition with a near optical finish. Electroformed metal is extremely pure with superior properties over wrought metal due to its refined crystal structure. Multiple layers of electroformed metal can be molecularly bonded together, or to different substrate materials to produce complex structures with ‘grown-on’ flanges and bosses. 

For electroforming you will require less powerful, but more accurate equipment. You can find further information on the ‘Electroplating’ page or can contact us at: